ARMY TM 9-6115-639-13
AIR FORCE TO 35C2-3-386-51
MARINE CORPS TM 10155A-13/1
5-8. PERMANENT MAGNET ALTERNATOR MAINTENANCE
This task covers removal, inspection, and installation.
Tool Kit, Master Mechanics
Generator set shut down (Para. 2-9)
(Item 3, App. B, Sect. III)
Battery cables disconnected
Shop Equipment, Automotive Maintenance
Cable disconnected for SLAVE RECEPTACLE
(Item 4, App. B, Sect. III)
Puller, Mechanical (Item 6, App. B, Sect. III)
Adhesive, Loctite (Item 16, App. E)
Tag and disconnect alternator output leads (1, 2, 3, 4, Figure 5-2).
Using a #4 metric allen wrench, remove cover (5) by removing six screws (6). Use care when removing
cover to prevent damage to alternator output leads.
Rotor assembly (11) is held in stator (14) by magnets. The rotor assembly must be
completely removed from stator, or magnets will pull it back into place.
Release rotor assembly (11) from engine shaft by removing screw (9) and washer (10). Using a
mechanical puller, remove rotor assembly (11) completely from stator (14).
Loosen clamping ring (13). Remove stator (14) from engine adapter (18) by removing six screws (12).
Remove engine adapter (18) from engine by removing four screws (15), lockwashers (16), and washers
Inspect alternator components for obvious damage. Clean as required to view all components carefully.
Look for signs of excessive wear or electrical short.
Inspect electrical wiring for cuts, crimps, bare wire, or other damage. Inspect wiring insulation for
damage. Ensure all connectors and terminal lugs are securely attached.
Inspect all components for corrosion. Check attaching parts for crossed, stripped, or damaged threads.
Inspect edge gasket (8) for damage. Inspect label (7) for legibility. Replace as required.
Remove and replace any component that is suspect.